DoAll TF-2025M User manual

TF-2025M
Serial No: 543-99101 to
Band Sawing Machine
Instruction Manual

DAMAGE CLAIM PROCEDURES
VISIBLE DAMAGE AT THE TIME OF DELIVERY:
1. Note damage on carrier’s delivery receipt. Accept the shipment. It can be returned later if repairs
are not possible in the eld.
2. Request a “damage inspection” from the delivery carrier:
a. The carrier will send his own people or contract an independent agency to make the
inspection.
b. The inspector will request a signature on the report and leave a copy.
c. The carrier “damage inspection” report is not nal. If additional damage is found when
repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.
3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.
4. If possible, take photographs of the damage and keep them for your les. Photos could possibly
prove a claim at a later time.
5. Keep a record of all expenses and be sure they are documented.
6. Repair damage in the eld whenever possible. Carriers encourage this to keep expenses down.
7. You have nine (9) months to le a claim.
1. You have fourteen (14) days to report damage not noted at time of delivery.
a. Report damage as soon as possible. This makes it easier to prove that it did not happen
at cosignee’s plant.
b. Inspect machine(s) carefully before moving from the receiving area. Again, if machine is
not moved, it is easier to prove your case.
2. Request a “damage inspection” from the delivery carrier:
a. The carrier will send his own people or contract an independent agency to make the
inspection.
b. The inspector will request a signature on the report and leave a copy.
c. The carrier “damage inspection” report is not nal. If additional damage is found when
repairs are started, contact the carrier for another inspection; or at least give them the
details of the damage.
3. Do not move the equipment from the receiving area and keep all shipping materials until carrier
“damage inspection” report is complete.
4. If possible, take photographs of the damage and keep them for your les. Photos could possibly
prove a claim at a later time.
5. Keep a record of all expenses and be sure they are documented.
6. Repair damage in the eld whenever possible. Carriers encourage this to keep expenses down.
7. You have nine (9) months to le a claim.
CONCEALED DAMAGE:

i
OPERATOR'S INSTRUCTION MANUAL
UNIVERSAL TILT-FRAME BAND MACHINE
MODEL FIRST SERIAL NO. LAST SERIAL NO.
TF-2025M 543-99101
PRINTED IN U.S.A. PB-486.4 (2-10)
For your information and future reference, pertinent data concerning your
machine should be written in the spaces provided above. This information is
stamped on a plate attached to your machine. Be sure to provide machine
model and serial numbers with any correspondence or parts orders.
Specications contained herein were in effect at the time this manual was
approved for printing. The DoALL Company, whose policy is one of continuous
improvement, reserves the right, however, to change specications or design
at any time without notice and without incurring obligations.
The following registered trademarks of the DoALL Company are used in this manual:
DoALL, Imperial Bi-Metal and Tensigage.
DoALL SAWING PRODUCTS
2375B TOUHY AVENUE
ELK GROVE, ILLINOIS 60007 U.S.A.
PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATING THE MACHINE!
For Sales, Parts and Service, call 1-888-362-5572

ii
TABLE OF CONTENTS
LUBRICATION
Lubrication Chart .................................................... 20
Lubrication Diagram ............................................... 21
MAINTENANCE
Replacing Saw Guide and Back-Up Inserts ........... 22
Hydraulic System .................................................... 22-23
Coolant Ststem ....................................................... 23
Machine Cleaning ................................................... 23
Machine Alignment ................................................. 23
Brush Adjustments .................................................. 23
Wear Plate Replacement ........................................ 23
Bandwheels ............................................................ 24
Cleaning Optional Chip Conveyor .......................... 24
Head Angle Display Calibration .............................. 24
TROUBLE SHOOTING .................................. 25-27
ACCESSORIES
Roller Stock Conveyors .......................................... 28
Vertical Guide Rollers (For Conveyors) .................. 28
Nesting Fixture ....................................................... 28-29
Chip Conveyor W/Coolant Reservoir ...................... 29
Mist Lubricator ........................................................ 30
Outboard Vise (Right Hand Vise) ........................... 30
Lift Rollers ............................................................... 30
Laser Line Option ................................................... 30
Fixed Head (Non-Tilting) ........................................ 30
3° Head Cant .......................................................... 30
MACHINE DIMENSIONS
Floor Plan ............................................................... 1
Front View .............................................................. 2
Side View ................................................................ 3
MACHINE FEATURES
Front and Side Views ............................................. 4
Head Assembly ....................................................... 5
Proximity/Limit Switch Locations ............................ 6
INSTALLATION
Location .................................................................. 7
OSHA Notice .......................................................... 7
Unpacking ............................................................... 7
Cleaning ................................................................. 7
Lifting ...................................................................... 7
Floor Installation and Alignment ............................. 7
Electrical Installation ............................................... 7-8
Hydraulic Installation .............................................. 8
Coolant Installation ................................................. 8-9
Preparation for Use ................................................ 9
OPERATION
Safety Precautions ................................................. 10
Using the Job Selector ........................................... 10
Cutting Capacity ..................................................... 11
Control Console ...................................................... 11-14
Saw Band Preparation ............................................ 14-15
Post Adjustment ...................................................... 16
Feed Force Adjustments ......................................... 16
Saw Head Approach Rate ...................................... 16
Coolant System ..................................................... 17
Hydraulic System .................................................... 17
Chip Removal ......................................................... 17-18
Idler Wheel Motion Detector ................................... 18
Typical Operation Procedures ................................ 18-19
How to read your serial number:

1
MACHINE DIMENSIONS
INCHES (± .03)
MILLIMETERS (± 1 mm)
FLOOR PLAN

2
FRONT VIEW
MACHINE DIMENSIONS (Continued....)
INCHES (± .03)
MILLIMETERS (± 1 mm)

3
MACHINE DIMENSIONS (Continued....)
SIDE VIEW
INCHES (± .03)
MILLIMETERS (± 1 mm)

4
MACHINE FEATURES
SIDE VIEW
FRONT VIEW

5
MACHINE FEATURES (Continued....)
HEAD ASSEMBLY

6
MACHINE FEATURES (Continued....)
PROXIMITY/LIMIT SWITCH LOCATIONS
REAR VIEW
HEAD
TOP VIEW

7
INSTALLATION
All the “left”, “right”, “front” and “rear”
designations in this manual are as viewed by
the operator looking directly at the teeth of
the saw band.
LOCATION
1. The floor area required by the machine is
approximately 105.00inches(2667.0mm)inwidth by
91 (2311.4) inches (4567.3 mm) in length. Machine
height for the machine is 107.65 inches (2734.3
mm). Refer to pages 1, 2 & 3 for further machine
dimensions.
2. Locate the machine to provide adequate space
for your sawing needs. Be sure also to provide:
(a) Sufcient clearance for loading and unloading
of stock; (b) Coolant tray installation; (c) Head
tilt; (d) Door openings; (e) Maintenance and
lubrication procedures; (f) Operation of any machine
accessories.
3. Provide ample space for roller conveyors and/or
other material handling equipment if supplied.
OSHA NOTICE!!
OSHA Regulation 1910.212 (5B).
 Machinesdesignedforaxedlocationshall
be securely anchored to prevent walking or
moving.
UNPACKING
1. The machine is fastened to and shipped on a wooden
skid. Overseas shipments are also crated.
2. Carefully remove all protective covers, strapping,
hold-down brackets, crating, etc., but DO NOT
remove the head support bracket until the machine
is placed in desired location. Then: (a) Remove all
bolts which fasten the machine to the shipping skid;
(b) Check around the machine for other removable
brackets, extramachinepartsorsupplieswhichmight
have been placed there for shipment; (c) Inspect the
machine and all parts for shipping damage. Claim
procedures are listed on this manual’s inside front
cover.
CLEANING
1. If necessary, use solvent to remove rust-preventive
coating applied to exposed bare metal surfaces
before shipment.
LIFTING
NEVER lift the machine by its sawing head.
1. There is three (3) forged 3/4-10NC eye-bolts for
lifting purposes. Two (2) are located in front on the
corners of the machine base and one (1) located in
the rear center near the head pivot pillow block.
2. Using chains attached to the eyes-bolts, it is
recommended that lifting and transporting of the
machine be done with an overhead hoist. Net weight
is approximately 7200 pounds (3265.9 kg).
3. The hydraulic power unit (aproximately 600
pounds (272.2 kg) and conveyors (if supplied as
optional equipment) can be lifted and transported
by overhead hoist, fork lift, or by other means that
provides adequate safety precautions.
FLOOR INSTALLATION and ALIGNMENT
1. While the machine is suspended by the overhead
hoist, thread the provided leveling screws into each
machine base foot and attach the jam nuts. Slowly
lower the saw into desired position.
2. Just prior to touching the ground, place a cast iron
foot pad under each of the leveling bolts. Lower
the saw completely onto the foot pads.
3. Place a level on the machine vise wear plate bed.
Insert leveling screws into the mounting pads and
make nal adjustments to level the machine in both
directions. Make sure weight bears evenly on all
mounting pads.
4. After the machine has been leveled, install anchoring
screws through the base pad holes next to the
leveling screws.
5. Remove the protective shipping bracket installed
to connect the saw head to the base frame during
shipping.
6. Install optional roller stock conveyor(s) if supplied.
These do not attach to the machine and should
beanchoredtotheoorseparately.

8
ELECTRICAL INSTALLATION
Electrical installation must be made by
authorized electrical maintenance personnel
only.
1. Refer to the machine specications plate on the saw
head frame to verify that the electrical supply circuit
will meet the voltage/phase/frequency/amperage
requirements listed. Abasic data plate is reproduced
on this manual’s introductory page.
2. The electrical supply to this machine must be a
dedicated circuit.
3. Power is connected to the main enclosure located
the rear of the machine.
4. The following are important disconnect
precautions:
The disconnect must be "ON" before the
machine will operate. Turning "OFF" the
disconnect will shut down the machine.
The enclosure must be closed and the
appropriate securing screws must be in place
before starting machine operation.
5. Turn the disconnect switch on the electrical cabinet
to "OFF". Then: (a) Loosen the screws at the right
door edge and open the door; (b) Familiarize yourself
with operation of the disconnect switch operating
handle, door interlock function, switch drive dog and
shaft/clamp operating positions.
6. Punch a one (1) inch (25 mm) diameter or larger
hole into the electrical cabinet. Then: (a) Bring
power wiring (L1, L2, L3 and ground) through the
hole (the cable and connector are to be supplied
by the customer). DO NOT bring the power cable
through any holes in the back wall. These are
for installation of future accessories.
Electrical Connections to Disconnect Switch.
7. Bring the power cable leads up to the disconnect
switch. Then: (a) Connect L1, L2 and L3 to their
respective terminals; (b) Connect the ground wire to
the ground terminal (refer to the electrical schematic
if necessary).
8. Place the operating shaft and operating handle of
the disconnect switch in the "OFF" position. Then:
(a) Close the electrical cabinet door and secure its
screws; (b) Now turn the electrical supply and the
disconnect switch to "ON" (no action will occur until
the Hydraulic Start button on the control console
has been pushed).
DO NOT start machine hydraulics until the
following “Hydraulic Installation” procedures
have been performed.
HYDRAULIC INSTALLATION
1. Position the hydraulic power unit behind and to the
right of the machine.
2. Check the hydraulic reservoir uid level in the
power unit. Capacity is 20 gallons (75.7 liters). If
the reservoir level is low (or empty): (a) Check to
see that the reservoir’s drain plug is installed tightly;
(b) Fill with multi-purpose automatic transmission
uid.
3. Connect the hydraulic lines between the machine
and power unit by matching tags on hoses to
connection points on the power unit. Refer to the
hydraulic schematic if necessary.
4. Remove the orange coupling guard between the
hydraulic pump and motor and turn the coupling to
assure free movement.
5. Prime the hydraulic pump by jogging the Hydraulic
Start and Hydraulic Stop pushbuttons. Check the
rotation of the hydraulic pump motor as indicated
on the arrow label.
6. If hydraulic pump motor rotation is reversed: (a)Turn
the disconnect switch off and remove power at the
source of electrical supply; (b) Interchange two (2)
of the L1, L2, or L3 leads to the disconnect switch;
(c) Restore power and perform Step 5 again.
7. As soon as hydraulic pump motor rotation is
correct, jog the Hydraulic Start and Hydraulic
Stop pushbuttons several times to make sure the
hydraulic pump is primed. Then allow the machine
to run for several minutes to remove entrapped air.
Also check for any hydraulic leaks at this time.

9
COOLANT INSTALLATION
1. Install the coolant pump by attaching it to the
mounting bracket inside the coolant tray with screws
provided.
Coolant Installation.
2. From the rear, slide the coolant tray between the
deector shields all the way in and under the saw
head with the coolant pump to the rear of the
machine.
3. Fill the coolant reservoir with 20 gallons (75.7 liters)
of oil or cutting uid recommended by the Lubrication
Chart. DO NOT let coolant spill over the tray and
ontotheoor.
 Thecoolantpumpintakemustbesufciently
submergedforcoolantowtoreachallareas
in the coolant system.
PREPARATION FOR USE
1. Check to be sure all safety guards, covers and doors
are in place, closed and/or secured.
2. Remove the protective Saw Cap from the saw band
by opening the upper bandwheel door and carefully
pull the cap off the saw band. Then closed the
bandwheel door.
3. Check to see that all other points listed by the
Lubrication Chart have been properly checked
and/or serviced.

10
OPERATION
SAFETY PRECAUTIONS
Warning Label - READ and UNDERSTAND.
USING THE JOB SELECTOR
1. Refer to the Job Selector chart on the front panel
of the control console for information about the
recommended blade pitch, band speed, and cutting
rate. This information is listed according to type
of material to be cut and its thickness. The Job
Selector also has a checklist for proper machine
operation and saw band break-in procedures.
JobSelectorrecommendationscanbeadjusted
to meet special sawing requirements and are
a general guide for correct cut-off sawing on
a properly-maintained DoALL saw. They are
based on cutting annealed, scale-free stock
using a Imperial Bi-Metal saw blade. Job Selector.

11
CUTTING CAPACITY
1. The standard machine's cutting capacity is:
• At 0° tilt: 20 inches (508.0 mm) wide by 25 inches
(635.0 mm) high for rectangular stock; 20 inches
(508.0 mm) diameter for round stock.
• At 45° tilt: 20 inches (508.0 mm) wide by 17 inches
(431.8 mm) high for rectangular stock; 17 inches
(431.8 mm) diameter for round stock.
• At 60° tilt: 20 inches (508.0 mm) wide by 11 inches
(279.4 mm) high for rectangular stock; 11 inches
(279.4 mm) diameter for round stock.
2. Cutting capacity may vary with addition of accessories
and will be noted when applicable.
Vise Capacity
1. The vise maximum opening is 20.50 inches (520.7
mm).
• Weight limit for the vise bed is approximately 1000
pounds (453.6 kg); 500 pounds (226.8 kg) for each
half evenly distributed with no impact.
Saw Band Recommendations
1. A high-speed DoALL Imperial Bi-Metal Super
Silencer saw band with protective Saw Cap is
supplied with the machine. Band length is 209
inches (5308.6 mm); width is 1-1/4 inches (31.7
mm); recommended gage is 0.042-inch (1.1 mm);
kerf is 0.085-inch (2.2 mm).
2. A machine in correct adjustment, good operating
condition and using proper cutting uid is essential
to efcient sawing.
3. Proper blade care should include: (a) Pushing uncut
stock away from the saw band; (b) Using correct
band speed, feed force and cutting uids during
operation; (c) Removing scale from stock before
sawing; (d) Keeping the protective Saw Cap over
blade teeth until installation time.
Consult your DoALL sales representative for
complete information about saw bands and
their applications.
CONTROL CONSOLE
Electrical Controls
1. Left Lift Roller (Optional). This selector switch
operates the left hand (inboard) lift roller in the "UP"
or "DOWN" positions.
2. Left Vise. This selector switch with "OPEN", "HOLD"'
and "CLAMP" settings operate the vise on the left
side (inboard side) of the saw band.
• The "OPEN" setting opens the vise jaws; the
"CLAMP" setting closes the vise jaws; and "HOLD"
stops vise jaw movement, it does not clamp
material.
• This vise must be clamped to start the band drive.
3. Saw Head Control. Use this selector switch
with "REV" (reverse), "HOLD" and "FWD/AUTO"
("FORWARD/AUTO") settings to regulate the
direction of saw head movement.
• Rotating the selector to "FWD/AUTO" or forward
moves the saw head forward or towards the sawing
area.
• Rotating the selector to "REV" or reverse moves
the saw head back or away from the sawing area.
• Turning the selector switch to "HOLD" stops all saw
feed motion.
4. Right Lift Roller (Optional). This selector switch
operates the right hand (outboard) lift roller in the
"UP" or "DOWN" positions.
5. Right Vise (Optional). This selector switch with
"OPEN", "HOLD"' and "CLAMP" settings operate
the vise on the right side (outboard side) of the saw
band.
• The "OPEN" setting opens the vise jaws; the
"CLAMP" setting closes the vise jaws; and "HOLD"
stops vise jaw movement.
Make sure the vise jaw is opened wide enough
when moving material through the vises.
6. Head Rapid Approach. Used in conjunction with
the Saw Head Control selector switch, pushing
and holding this pushbutton accelerates the rate
of speed the saw head moves towards the sawing
area.
• This pushbutton is active only when the Saw Head
Control selector is in the "FWD/AUTO" position. The
band drive does not have to be "ON" to operate.
7. Laser. This selector switch turns the line-up laser
"ON" and "OFF".
To avoid eye damage, DO NOT stare into the
laser beam.

12
CONTROL CONSOLE (Continued....)
Typical Pushbutton Panel.
11. Head Angle Rapid. Used in conjunction with the
Head Angle selector switch, pushing and holding
this pushbutton accelerates the rate of speed the
saw head moves while rotating the saw head.
12. Head Angle. This selector switch with "-", "HOLD",
and "+" settings regulate the direction of head tilt and
shows the angle in degrees on the display above.
Head Angle Orientation.
• Turn the selector to "-" or left causes the head to
pivot to the left or negative direction.
• Turn the selector to "+" or right causes the head to
pivot to the right or positive direction.
• Turn the selector to "HOLD" stops head movement
in either direction.
13. Band Speed Display. This display shows the
factory-set band speed in feet per minute or meters
per minute.
14. Band Speed. Turn this knob to adjust band speed
between 50 and 400 fpm (15 to 122 m/min.).
Rotate clockwise to "increase" the band speed;
counterclockwise to "decrease" it.
8. Post. This selector switch with "DOWN", "HOLD",
and "UP" settings regulate post movement.
• (a) Rotating the selector to "DOWN" lowers the
post; (b) The "UP" position raises the post; (c) The
"HOLD" position stops post movement.
When the saw head is rotated, make sure the
post is positioned to clear the material. Failure
to do so will result in damage to the post.
9. Operation. This selector switch with "MANUAL"
and "AUTO" settings determines the machine's
operating mode. Make your selection before starting
the band drive motor.
• Placing the selector to "MANUAL" will stop all
machine functions at the head forward position
following the completion of each cut.
• Placing the selector in "AUTO" permits a full cycle
mode following the completion of cuts; (a) The saw
band drive motor will stop; (b) The saw head will
return behind the vise jaw; (c) Hydraulics will remain
on.
10. Head Angle Display. This displays the angle of
the saw head in degrees from vertical.
• When the saw head is tilted to the left, the display
shows a "-" or negative angle; when tilted to the
right, no sign is shown or positive angle.

13
CONTROL CONSOLE (Continued....) 20. Hydraulic Stop. Pushing this red button turns off
the hydraulic pump.
21. Emergency Stop. Pushing this red mushroom head
pushbutton stops all machine motors (band drive,
hydraulic pump, coolant pump and optional chip
conveyor) simultaneously. To reactivate machine
motors:
• If the machine was operating in manual mode before
the Emergency Stop button was pushed: (a) Reset
the Emergency Stop button by turning the button
head clockwise; (b) Push the Hydraulic Start and
Band/Cycle Start buttons in sequence.
• If the machine was operating in automatic mode
before the Emergency Stop button was pushed:
(a) Reset the Emergency Stop button by turning
the button head clockwise; (b) Push the Hydraulic
Start button; (c) Position the stock as necessary;
(d) Clamp both index and xed vises; (e) Push the
Auto (F6) button; (f) Push the Band/Cycle Start
button.
Other Controls
1. Band Tension. This selector switch with "OFF",
"HOLD" and "ON" settings is used when changing
saw bands. The control is located on the rear side
of the column and accessed from the left side.
• Turning the selector to “OFF” releases band tension
and enables saw band removal or installation.
• The “HOLD” setting stops band tension cylinder
movement and allows the operator to position the
saw band over the bandwheels.
• The “ON” setting pressures the cylinder and
establishes band tension required for cutting. DO
NOT operate the band drive motor unless band
tension is on.
• The Band Tension selector must be "ON" before
the saw head will traverse.
Hydraulic Control Panel
1. Variable Vise Pressure. This control valve and
gauge are used to adjust vise clamping force against
materials which cannot tolerate full vise clamping
pressure (examples are thin-walled tubing, pipe,
light structurals, etc.).
• Clamping pressure is set by loosening the lower
locking knob, then turn the upper adjusting knob until
the desired pressure is shown by the indicator gauge.
Turn the knob clockwise to "increase" pressure;
counterclockwise to "decrease" pressure.
15. Chip Conveyor (Optional). This selector switch
with "REVERSE", "OFF", and "FORWARD" settings
operate the optional motorized chip conveyor.
• Turning the selector to the "FORWARD" position
moves the chip conveyor belt to the rear of the
saw and deposits the chips into a container. This
is the normal operating position and recommended
that it is in the "FORWARD" position during sawing
procedures.
• Turning the selector to "REVERSE" moves the chip
conveyor belt towards the front of the machine. Use
this setting only to clear a temporary situation.
• The center position turns the chip conveyor
"OFF".
16. Band/Cycle Start. Push this green button to start
the band drive motor. The button will be illuminated
when the band drive motor is operating. Allow
the motor to accelerate to operating speed before
starting a cut.
• The following conditions must exist before pushing
the Band/Cycle Start button: (a) The Emergency
Stop pushbutton is reset (turn the button head
clockwise);(b) Hydraulics must be on; (c)All doors
and covers/guards must be closed or in place; (d) A
saw band must be installed and the Band Tension
selector must be at “ON”; (e) The vise(s) must be
clamped.
17. Band/Cycle Stop. Push this red button to stop the
band drive motor.
18. Coolant. Four position selector switch with "AUX",
"OFF", "BAND ON", and "ON" settings.
• (a) "BAND ON" allows the ood coolant system to
operate when the band drive motor is running; (b)
"ON" allows the ood coolant system to operate
without the band drive motor running; (c) "AUX" is
used for the optional cutting lubrication system; (d)
"OFF" turns off either system.
19. Hydraulic Start. Push this green button to start the
hydraulic pump motor (the button will be illuminated
when the hydraulics are operating). The hydraulic
pump motor must be on to operate any machine
functions.
• Before starting the hydraulics, the Emergency Stop
pushbutton must be reset (turn clockwise).

14
CONTROL CONSOLE (Continued....)
Typical Hydraulic Control Panel.
2. HeadApproach. Thisvalveregulatesthesaw head’s
forward rate. Turn the knob counterclockwise to
“increase” the velocity; clockwise to “decrease”
it.
3. Coolant. This valve regulates coolant ow to
the upper saw guide and ushing hose. Turn the
valve counterclockwise to “increase” coolant ow;
clockwise to “decrease” the ow.
4. Feed Force. This valve and gauge are used to
regulate the amount of pressure being placed
by the saw band against the workpiece. Turn
the knob clockwise to “increase” pressure;
counterclockwise to “decrease” the force desired
as shown on the gauge. The valve’s lower locking
knob helps maintain the setting.
Optional Material Handling Controls
1. Conveyor Speed. This selector switch with "LOW"
or "1" and "HIGH" or "2" settings regulate the speed
of the conveyor(s).
• When the selector is in the "LOW" or "1" position,
the conveyor maximum speed is reduced to about
30%.
2. Infeed Conveyor Enable. This selector switch with
"ON" and "OFF" settings allows the operator to turn
the power off or on to the conveyor. This is used
in conjunction with the Conveyor Speed/Direction
control.
3. Outfeed Conveyor Enable. This selector switch
with "ON" and "OFF" settings allows the operator to
turn the power off or on to the conveyor. This is used
in conjunction with the Conveyor Speed/Direction
control.
4. Conveyor Speed/Direction. This two position
joystick allows the operator to adjust the conveyor
speed and direction of material owing through the
machine.
• The Infeed and/or Outfeed Conveyor Enable
selectors must be "ON" for this control to operate.
• Moving the joystick to the right will convey the
material to the rear of the machine; moving the
joystick to the left will convey the material forward
on the system.
• The rate of travel in either direction is controlled
by how far the joystick is moved from center. The
farther from center, the faster the rate of travel.
SAW BAND PREPARATION
Saw Band Recommendations
1. A high-speed DoALL Imperial Bi-Metal Super
Silencer saw band with protective Saw Cap is
supplied with the machine. Band length is 209
inches (5308.6 mm); width is 1-1/4 inches (31.7
mm); recommended gage is 0.042-inch (1.1 mm);
kerf is 0.085-inch (2.2 mm).
2. A machine in correct adjustment, good operating
condition and using proper cutting uid is essential
to efcient sawing.
3. Proper blade care should include: (a) Pushing uncut
stock away from the saw band; (b) Using correct
band speed, feed force and cutting uids during
operation; (c) Removing scale from stock before
sawing; (d) Keeping the protective Saw Cap over
blade teeth until installation time.

15
SAW BAND PREPARATION (Continued....)
Consult your DoALL sales representative for
complete information about saw bands and
their applications.
Blade Guards
1. The machine has several guards for operator safety
and protection. All guards must be in place before
any sawing procedure is started.
2. Post Guard. This guard is hinged and attached to
the upper saw guide and extends up towards the
bandwheel.
3. Post Bellows. Mounted in the right side of the
upper saw guide and also extends up towards the
bandwheel.
4. Column Guard. This guard is mounted on the head
column and located between the bandwheels.
5. Cover Guard. This guard with a interlocked door
is located in the left rear of the machine.
DO NOT defeat the purpose of any guard
or safety devise. They are there for YOUR
PROTECTION!
Saw Guides
1. The upper and lower saw guides both have zero-
clearance,carbide-faced,spring-loaded inserts. The
inserts provide support necessary to help maintain
sawing accuracy. Back support is provided by the
pivoting carbide back-up inserts.
Typical Saw Guide.
Saw Guide Insert Adjustment
1. Loosen the adjustment screw (turn
counterclockwise) on each saw guide. Turn the
insert adjustment screw clockwise until tight and
then back off 1/4 turn. This applies to both upper
and lower saw guides.
Saw Band Removal
 Alwaysuseextremecarewhenhandlingsaw
bands. Wear gloves.
1. Before removing the saw band, set the machine to
the following conditions: (a) Hydraulics are "ON"; (b)
Band drive motor is "OFF"; (c) Coolant is completely
shut off; (d) Saw head is vertical and completely
retracted.
2. Turn the Band Tension selector switch to "OFF".
Then: (a) Open the upper bandwheel; (b) Open
the hinged post guard; (c) Loosen the saw guide
insert adjustment screws; (d) Carefully remove the
old, worn or broken saw band from between the
saw guide inserts and both bandwheel; (e) Carefully
work the saw band out from the column guard and
dispose the saw band immediately.
Saw Band Installation
 Alwaysuseextremecarewhenhandlingsaw
bands. DO NOT attempt to change saw bands
while the band drive motor is running.
1. Carefully follow all "Saw Band Removal" procedures.
Then: (a) Use the Flushing Hose to clean areas
around the saw guides and inserts, plus the drive
and idler bandwheels.
2. Carefully position the saw band around the drive
and idler bandwheels with the saw band's back edge
resting against each bandwheel's rear ange. Then:
(a) Maneuver the saw band into the column guard;
(b) Turn The Band Tension selector switch to "ON"
to apply just enough tension to hold the saw band
in position, then turn the selector to "HOLD".
3. Slip the saw band between the saw guide inserts
by twisting it 90° so the blade teeth are facing the
front of the machine and pointing downward. Then:
(a) Turn each saw guide insert adjustment screw
clockwise until tight and then back off 1/4 turn;
(b) Remove the protective Saw Cap from the saw
band; (c) Close the hinged post guard and then
the bandwheel door; (d) Turn the Band Tension
selector switch to "ON" to apply full tension to the
saw band.

16
Reducing Cutting Rate & Band Speed for Pipe, Tubing
and Structurals
1. Increasing loading per tooth occurs when sawing
thin stock sections. Although the blade teeth can
bear some overloading, a cutting rate reduction
must be made.
2. Proceed as follows when it becomes necessary to
modify solid section sawing recommendations: (a)
Measure the thinnest stock section to be cut; (b)
Apply the corresponding percentage factor from the
chart below; (c) Use a high band speed, but never
exceedthemaximumspeedrecommendedfor
stock sections of the same size.
SECTION FACTOR TO APPLY
THICKNESS TO MINIMUM CUTTING
RATES GIVEN BY JOB
SELECTOR*
Up to 3/16 inch 40%
(0 to 4.8 mm)
3/16 to 3/8 inch 50%
(4.8 to 9.5 mm)
3/8 to 5/8 inch 60%
(9.5 to 15.9 mm)
5/8 to 1 inch &over 70%
(15.9 to 25 mm & over)
*Based on 5 inch (127.0 mm) solids.
Cutting Rate to Thickness Relationship.
SAW HEAD APPROACH RATE
1. After the stock has been positioned for cutting and
the Saw Head Control selector is placed at the
"FWD/AUTO" setting, the saw head's approach
(traversing) rate is regulated by the Head Approach
valve.
2. Correct head approach is important for helping: (a)
Determine overall cutting accuracy and nish of
cut; (b) Improve blade life by eliminating breakage
and tooth strippage at the cut's start and break-out
points.
3. To move the saw head if the band drive motor
is not running: (a) Place the saw in "MANUAL"
operating mode; (b) Move the Saw Head Control
selector to "FWD/AUTO"; (c) Make the desired
Head Approach valve setting; (d) There must be
some Feed Force setting.
4. Push the Band/Cycle Start button and run at a
very low speed to check for proper band tracking
against the each bandwheel rear ange.
POST ADJUSTMENT
1. Post and upper saw guide height is regulated by
the Post selector switch on the control panel.
2. Sawing results will generally be more satisfactory if
the post and upper saw guide are kept as close as
possible to the material being cut. Doing so helps
reduce saw band vibration and contributes to more
accurate sawing.
When the saw head has been tilted, make
sure the post and saw guide will clear the
material.
FEED FORCE ADJUSTMENTS
1. Feed force is the pressure exerted by the workpiece
against the saw band's cutting edge. It is controlled
hydraulically and regulated with the Feed Force
valve. Turn the valve clockwise to "decrease"
pressure, counterclockwise to "increase" it.
2. The following are important factors to consider when
setting or adjusting the Feed Force valve:
• Turn the Feed Force valve to a low setting if the
correct feed force is not known. The operator can
then increase or decrease pressure during operation
to obtain the best cutting rate consistent with desired
blade life and stock cut nish. Always be sure to
take a good chip.
•Never start a cut with the maximum Feed Force
valve setting. Blade damage may occur.
• Certain work-hardening materials will require a
moderately heavy initial Feed Force valve setting to
assure immediate penetration of blade teeth. Light
feeds on these materials may cause the blade to slide
over the stock resulting in saw band damage.
• Generally, top performance from a sharp saw band
results from relatively low Feed Force valve
settings. It will be necessary to increase the setting
as the saw band becomes duller. This will help keep
the cutting rate constant throughout the life of the
saw band.
• Feed force adjustments are not necessary for
changing stock cross-sections. A balancing valve
enables the saw band to maintain a uniform cutting
rate.
SAW BAND PREPARATION (Continued....)